For Your Shop 2 3 Shop-Tested Benches, Racks, Organizers, and More

WOOD m a g a z i n e’ s Great Projects for Your Shop 2 3 Shop-tested benches, racks, organizers, and more...

Right-angle router-table push pad p. 10

Proven plans by the editors of WOOD

Supplement to WOOD® Magazine woodmagazine.com 1 WOOD Magazine's Great Projects for Your Shop Contents 1 Mobile utility bench P.4 2 Folding assembly table 3 Multilayered lumber rack and sheet-goods holder 4 Rolling storage cart 5 Easy, attractive drill-bit cabinet 6 Benchtop sanding-disc caddy P.6 7 Built-to-fit sandpaper holder 8 Tablesaw tapering jig 9 Exact-width dado jig 10 Right-angle router-table push pad 11 Zero-clearance cutoff guide 12 At-the-ready router rest 13 Hang-and-go lathe-tool holder P.1 14 Easy-access router-bit storage 15 Round and ready drill-bit carousel 16 Workshop drawer organizer 17 Movable task-light support 18 Wall-hung tape dispensers P.10 19 Portable glue/towel center P.13 20 Edge-protecting chisel rack 20 pencil box with sharpener support 21 Handy hardware bin P.17 21 Hanging glue box

Great Projects for Your Shop Mobile utility bench

The perfect size for smaller tasks, this handy bench rolls—and then stays— wherever you need it most.

or a shop with limited space, or when you need some additional work- F surface for a project, this small bench fills the bill. With casters on one end only, you can easily move it like a wheelbarrow, yet the bench is rock-solid when lifted off the caster with the load leveler. The bench shown here features alder sides, exterior- grade ¾" medium-density overlay (MDO) for the carcase, and construction-salvage oak 2×4s for the benchtop. Laminating the top with 2×4s makes for a more stable than a solid slab.

Project design: Dale Faulstich, Sequim, Wash.

18" 54"

3½" 2x4s

⁄" lag screw 36" #17 x 1½" brad 2½" long

#17 x 1½" brad 14½" 1½ x 3 x 24" caster cleat 1½ x 3 x 30" leveler board 27" 3" 34½" Plywood 27" 3" 1½"

Solid stock 3" locking swivel caster 5½" Load Solid stock leveler 6" 1½" 24" 1½" 4"

woodmagazine.com 1

I talked with Mr. Faulstich a few times to get info on his bench, he told me all he used was a brad nailer to put it all together, 100505676.ai he explained he was going for speed and ease of assembly, 2-09 he said he used no screws

FILENAME : FaulstPrj1_#100505676.eps Filename: Faulstich bench Date: 11-07 R LeMoine Lorna J . 11-6-07 Folding assembly table

¼" Baltic birch plywood covered with laminate Use it. Fold it. Then Table leaf levelers store this table in a 24"

TOP minimum of space.

84" his versatile table with a removable worksurface allows Jeff Tobert some Lattice T additional space to assemble projects, 1¼" frame and gives him a larger outfeed space when ¾" aligned with the regular outfeed table on his tablesaw. Continuous hinges allow the 4" SIDE folding end assemblies to collapse for easy ASSEMBLY storage. Each leaf of the tabletop consists of two plywood skins over lattice frames, 30" Pocket-hole screws covered with plastic laminate. Install cabinet levelers at each corner so you can adjust 60" ¼" dowels with mating holes in top the table to match just about any uneven 52" surface inside—or outside—your shop. 4" 4" Heavy-duty 17¼" NOTE: Jeff used continuous (piano) hinges cabinet leveler for his table, but to save money, consider END ASSEMBLY using less-expensive butt hinges.

Project design: Jeff Tobert, Spruce Grove, Alta. Continuous hinges 30" long joining side assemblies 30" Continuous hinge to end assemblies 30" long joining both halves of 4" end assembly

2 Great Projects for Your Shop

100505693.ai Filename: Tobert knockdownTBL 2-09 R LeMoine 1-3-07 KNOCK-DOWN COLLAPSIBLE WORKTABLE

FILENAME:TobertPj1_#100505693.eps Filename: Tobert knockdownTBL Date: 10-07 R LeMoine Lorna J . 10-30-07 Multilayered lumber rack and sheet-goods holder

1½" rabbet #8 x 1½" F.H. wood screw ¾" deep Pack lots of wood in a 72"

1½" dado minimum of space. ¾" deep ¾" hole 3" deep drilled at a 87° ¼" lag screw his wood-storage system keeps sheet 3° angle 6" long goods and boards close at hand but Toccupies minimal space. The upright component stores long lumber. It mea- ¾" pipe 16" long sures 8' high × 6' wide. Attach 2×4s to the wall and drill ¾" holes 3" deep angled 2x4s upward about 3° into the 2×4s. Then insert 16"-long pieces of ¾" black pipe. Fasten a 1½ x 5½ (2x6) x 48" 1×4 horizontally along the rack face toward the bottom, creating a small cavity between the vertical members where you can store 96" flat stock, dowels, and scraps of fine woods. 4" hinges The second component is a swinging sheet-goods holder. Make a frame of one vertical and one horizontal 2×6, faced on each side with a 4×4' sheet of plywood cut on the diagonal. The vertical frame piece attaches to the 2×4 on the wall with hinges. ½ x 48 x 48" A 3" swivel caster attached near the end of plywood the horizontal frame piece allows the unit to swing out easily, providing ready access to materials stored behind.

1½ x 5½ (2x6) x 46½" ¾ x 3½ (1x4) x 72" Project design: Dale Heisinger, Orcas Island, Wash. 3" swivel caster 3½" notch ¾" deep woodmagazine.com 3

WOOD ST ORA GE WALL SYSTEM (1x4)

100205901.ai Date: 3-09 FILENAME:Tip2_#100205901.eps Date: 7-06 Lorna J . Filename: Heisingershop tip 1 R LeMoine 6-21-06 Rolling storage cart

This shop helper brings order to chaos.

he design of this unit revolves around goods usage. Rout a 1/8" round-over along plastic storage tubs like those sold in the one exposed edge of each 11/2×11/2" Thome centers and large discount cleat and along the top edge of each 3/4×3/4" stores. Our version houses Rubbermaid cleat where shown. (The round-over on the Roughneck Storage Tote 3-gallon/11.3-liter interior cleats allows the tubs to slide easier.) containers, but just about any kind will do. Then, drill the countersunk mounting holes Just be sure to adjust the project dimensions through all parts where noted. Glue and to fit the tubs you select. screw the dividers between the two sides. The entire project, minus the optional Next, attach the top, bottom, center parti- shelves and cleats, is built from two sheets tions, and cleats. Mount the interiorCutting support Diagra m of medium-density fiberboard (MDF), but cleats, allowing about an inch or two of 3/4" birch plywood would also work well. clearance, from top to bottom, between Start by cutting the parts to size as noted in containers. Attach the casters. Drawing 1. See Drawing 2 for optimal sheet- Project design: Bernard Monneau, Calgary, Alta.

1 exploded view

*26¼" Center partition Divider TOP #8 x 2" #8 x 2" F.H. CLEAT Cutting Diagra m F.H. wood *21¾" wood screw 1½ x 1½ x 32¾" Side screw Top/bottom

1" *10½" DIVIDER 16" ¾" ⁄" round-over ¾ x 49 x 97" Medium-density berboard 7¼" (MDF) (2 needed) SIDE ¾" SUPPORT CLEATS 21 CUTTING DIAGRAM ¾ x ¾ x 16" 7¼" (48 needed) SIDE *Dimension Center partition Divider will depend upon the size of your tubs. ⁄" round- 68" Side overs Top/bottom

#8 x 1¼" F.H. 32¾" CENTER 16" wood screw #8 x 2" F.H. PARTITION wood screw 16" ¾ x 49 x 97" Medium-density berboard (MDF) (2 needed) 4" DIVIDER CLEAT Outside cleats swivel caster 1½ x 1½ x 32¾" 1½ x 3½ x 72" Pine (4 bd. ft.) Inside cleats BOTTOM 32¾" ⁄" round-over ¾ x 5½ x 96" Pine (4 bd. ft.) *26¼" Inside cleats 4" xed caster #8 x 2" F.H. wood screws ¾ x 3½ x 96" Pine (2.7 bd. ft.)

Outside cleats

1½ x 3½ x 72" Pine (4 bd. ft.) 4 GreatInside Projects cleats for Your Shop

¾ x 5½ x 96" Pine (4 bd. ft.) Inside cleats

100.ai ¾ x 3½ x 96" Pine (2.7 bd. ft.) Date: 5-09

FILENAME:166GIFY StorageCD.eps 100 Date: 7-05 Date: 5-09 Lorna J.

FILENAME:166GIFY Storage1.eps Date: 7-05 Lorna J.

100.ai Date: 5-09

FILENAME:166GIFY StorageCD.eps Date: 7-05 Lorna J. Easy, attractive drill-bit cabinet Here’s a great way to keep everything you need for drilling tasks in one place.

f you’ve ever discovered that you had wasted money by buying the same drill Ibit more than once, you may need a cabinet for organizing all your bits and accessories. With everything in its own spot, taking inventory of your drill bits takes only a glance. This cabinet is made of Baltic birch plywood (drawer fronts plus side, back, and door panels); pine (drawers and door trays); and walnut (drawer handles) for an attractive appearance. But use whatever materials suit your tastes. Likewise, make as many or as few shelf-holding dadoes as you need to match the number and sizes of the bits you own. Putting a few extra dadoes in the sides of the doors at the time of construction allows you to change 8 ⁄" 8½" the internal shelf arrangement as your 16¾" needs change.

Project design: Tom Whalley, Urbandale, Iowa ¼" dadoes 24⁄" ¼" deep 15¼"

¾" plywood 4¾" 1¼ x 1½"

¼" hardboard

24⁄" 7¼" ¼" plywood ¼" groove ¼" deep

16¾" Magnetic 4½" catch ¼" rabbet ¼" deep

1½" 10" ¼ x ½ x 9⁄ " drawer guides 15⁄" ½" groove ⁄" deep

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Filename: WHALLEY projects 1 100505696.ai R LeMoine Date: 5-09 1-3-07 FILENAME : Whalle yPj1_#100505696.eps Date: 10-07 Filename: WHALLEY projects 1 Lorna J. R LeMoine 10-15-07 Benchtop sanding-disc caddy

Store, wrap, and tote your sanding needs with this single portable unit.

he horizontal layout of this nifty sandpaper holder maximizes both Tspace and organization. Hook-and- loop sanding discs stand on edge within their own compartments, separated by 3⁄16" hardboard dividers that slide neatly and snugly into dadoes on the top and bottom shelves. Self-adhesive rolls wrap around the long dowel on the top, while abrasives for a detail sander stack up on vertically oriented dowels glued into holes on top of the caddy.

Project design: Walt Segl, Pleasant Valley, Pa.

¾" hole ⁄" dowel 2¾" long

½" ½" dado ¼" deep ⁄" hole ¾" dowel 23" long ½" deep 6½"

5 ⁄"

10" ⁄" rabbet ¼" deep ⁄" hardboard along back edge ½" rabbet ¼" deep 6⁄"

⁄" rabbets ¼" deep

½" 6½"

⁄" dado ¼" deep 6½" 20" 2⁄" 2 ⁄"

6 Great Projects for Your Shop SANDPAPER HOLDER

100505690.ai Date: 5-09

FILENAME : SeglPj2_#100505690.eps Date: 10-07 Filename: SEGL Projects 2 Lorna J. R LeMoine 10-15-07 Built-to-fit sandpaper holder

This organizer stores abrasives close at hand and keeps them tightly rolled till ready for use.

ecause they’re designed to mount on a round drum, abrasive strips are Bbest stored rolled up until needed. This rack, sized for an exact fit in the base of the drum sander shown at right, has numerous small compartments that keep the sandpaper strips from uncoiling. To make one of your own, carefully measure the stand or base of your sander and adjust the drawing, below, to match your machine’s dimensions.

Project design: Tom Whalley, Urbandale, Iowa

#8 x 1½" F.H. wood screw

½ x 1½" 1½" notches 3"

4¼ " 4" ½" ½"

½" Length to t inside of tool cart 2x4

½" dadoes quick tip: sanding grit id ¼" deep When cutting sandpaper into smaller pieces, you can bet several won’t have the Length to t inside of grit number on the back. Before you cut tool cart the sheet, scribble a crosshatch pattern on the back with a colored marker. Each cut ½" rabbet ¼" deep piece then will have colored lines on the back. Use a different color for each grit, and make a color-key chart to keep with the sandpaper. Then, you can readily identify the grit. —Daniel Angert, Orlando, Fla.

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Filename: WHALLEY projects 3 R LeMoine 100505698.ai 10-17-07 Date: 3-09

FILENAME : Whalle yPj3_#100505698.eps Filename: WHALLEY projects 3 Date: 10-07 R LeMoine Lorna J . 10-15-07 Tablesaw tapering jig

Here’s an easy way to make repeatable angled rip cuts.

f you don’t have a tapering jig for your tablesaw, you easily can make one from scrap to safely and accurately cut tapers Ion legs and other angled workpieces. Referring to the drawing, cut the base and three cleats to the sizes shown from 1/2" plywood. Cut the handle from 3/4" scrap. Drill mounting holes and screw the handle to the base, where dimensioned. Using a tapered table leg as an example, you'll want to mount the cleats to the base so they are snug against it. Adhere the leg to the base with cloth-backed double-faced tape, aligning the top and bottom of a marked tapered side of the leg with the edge of the base, where shown. Make sure you position the leg with one mortise down and the other facing the blade. Then screw-mount the cleats Start of cut to the base, where dimensioned, tight against the leg. With the leg still taped to the base, position your tablesaw fence to align the edge of the base flush with the inside face of the blade. Cut the taper, as shown in the photo. Then, rotate the leg to align the second marked side with the base, Jig base aligned with and cut again. To keep the legs securely attached, replace the inside face of tape as needed. blade

Project design: Jeff Mertz, WOOD® magazine

½ x 1 x 6" cleats mounted tight against ½ x 8 x 36" #8 x ¾" F.H. leg after positioning leg on base ⁄" shank hole, wood screw plywood countersunk ½ x 1 x 3" cleat mounted tight BASE 1½" 14" 3" 1" against leg bottom after positioning HANDLE ¾" 6" leg on base

7" Position leg with top 2" of marked taper here. 4½" Location of leg ⁄" pilot hole #8 x 1¼" F.H. Cloth-backed ¼" deep double-faced tape wood screw ¾" Align marked taper line on bottom of leg with edge of base. Watch a FREE 11-minute video using three other tablesaw jigs at: woodmagazine.com/tsjigsvideo ▲

8 Great Projects for Your Shop

TAPER JI G TableShelfJig_#100505861.ai Date: 3/09

FILENAME:166Table&ShelfJig.eps Date: 6-05 Lorna J. Exact-width dado jig

Adjustability is the key for a perfect cut every time.

ere’s a jig for routing bookcase- or cabinet-side dadoes that exactly Hmatch the thickness of your shelf stock. Better yet, no special bits are needed. Just use an ordinary straight bit and a guide bushing. (We used a 1" guide bushing and a 1/2" straight bit.) To start, cut a 3/8" rabbet 3/8" deep along the inside edge of both guide rails (A). Then, complete the jig, as shown in Drawing 1. To customize the rails for a different bushing and bit, install them in your router and trim the protruding lip of the rabbet in the guide rails, as shown in the Dadoing Detail in Drawing 1a. The remaining lip will now match your bushing/bit combo. To adjust the jig for the exact width of your shelf stock, slip the jig over the shelf stock, as shown in the Exploded View. Pull the guide rails (A) tightly against the stock and tighten the wing nuts. Slip the jig off the stock and clamp the jig onto the piece being dadoed, centering the opening between the rails (A) over the marked dado on the side panel. Adjust the depth of cut with your router sitting on top of the rails. Start the router and make one pass 1 exploded view with the guide bushing riding against one of the rabbeted rails. Make a second pass, riding the bushing against the opposite ‡ x 2‹ x 12" rabbeted rail. 3ﬁ" C Project Design: Wayne Kovi, Wallingford, Conn. ‹" slot Shelf stock 2" long

ﬂ" hole ‹" deep N 1a dadoing detail with a ‹" hole ‹" wing nut ‹" slot centered B O 2" long inside

C P B 3" A D Q ‹" washer Guide ﬁ" E R rails #8 x 1‹" F.H. A A ›" rabbet wood screws, S ›" deep countersunk F Side panel ‡ x 2‹" guide rails A 20" long G T 1" guide Shelf dado bushing ﬁ" straight bit ‹" carriage bolt 2" long H U V ‡ x 2‹ x 6" B I J W X K woodmagazine.com 9 Y L Z DADOING DETAIL ADJUSTING THE JIG M

WD320770.eps

DRAWING NO. FILENAME:_#100.eps Filename: SHELFJIG Date: 6-06 R Lemoine Lorna J. 3-21 Right-angle router-table push pad

Cleanly cut 90° ends with precision and ease.

ot only does this simple guide keep stock perfectly square to the router Nfence, it also supports the back edge of the routed stock to minimize tear- out. Plus, it keeps your hands safely away from the spinning bit. To build it, cut the pieces to the sizes and shapes noted on the drawing. Cut several extra supports so you can replace them as the inside end gets routed away. For a comfortable grip, rout the edges of the handle with a 1/4" round-over bit. Screw but do not glue the support to the base. Take special care to place the attachment screws for the support so that they will never come into contact with your larger bits. Then, screw the handle to the base. Sufficiently countersink the screws securing the handle to the base so they don’t scratch or catch on the top of your router table.

Project Design: Tom Clark, Sarasota, Fla.

R=‡" 6" HANDLE 3"

‹" round-overs R=‡" 1‹" ‡" A N 3" 2fi" B O 11" P 4‡" C ¸" shank hole, 2fi" countersunk ¸" shank hole, countersunk D Q BASE on bottom side, with a 7⁄64" pilot hole ‡" deep in handle E R 7⁄64" pilot holes ‡" deep ‡" S F 1fi" 2" G T 9‹" H U #8 x 1fi" F.H. wood screw V I #8 x 1fi" F.H. 9‹" wood screw J W SUPPORT X ‡" K Y L Z 10 Great Projects for Your Shop M

RIGHT-ANGLE ROUTER-TABLE PUSH PAD

FILENAME:177GIFYPush_#100504616.eps Date: 12-06 Filename: 177 routerpushpad GIFY Lorna J. R LeMoine 12-12 A N

B O CIRCULAR SAW STRAIGHTEDGES

C P D Q

E R S F G T

H U V I Zero-clearance cutoff guide J W X K This custom-fit guide helps 2 end view Y Line up saw against fence and cut to remove waste. L ﬁ" Z eliminate chip-out. 3" 2" 6" M ﬁ" FENCE

A N 4‹" 3fi" 3" 8" hese two cutoff guides, a 4- and 11" B O 8-footer, handle a range of workpiece END VIEW TC P lengths. You can make both guides 1 exploded view 107" to custom-fit your circular saw and router D Q #8 x ‡" F.H. Edges flush from a single sheet of 1/2" plywood. A sheet wood screw withE Rsanded faces works best. 96" BASE 2" SnapS a chalk line along the entire length ¸" shank hole, ofF the sheet 11" from the edge. Using your countersunk circularG T saw, rip along that line. Now, use 107" the factory edge of the cutoff piece as a H U guide for your circular saw to make the V 48" restI of the cuts.FILENAME:Straight2a_#100205684.eps From the remaining plywood piece, rip two strips 2" wide, two 2" J W Date: 5-06 Filename: 172 straightedges59fi" 1 strips 8" wide, andLor naone J. strip 11" wide. R #8LeMoine x ‡" F.H. X wood screw K Cut the strips to the dimensions shown 4-21 in DrawingsY 1 and 2 and assemble the L 5‡" guides,Z removing any glue squeeze-out. 5‡" M Once dry, secure each guide to your 8' GUIDE fi" workbench, allowing clearance for the saw fi" 7 4' GUIDE blade. Using your circular saw with the blade ⁄64" pilot hole ‹" deep 8" you would commonly use, rip the edge on the wider side opposite the fence, as shown ¸" shank hole, countersunk in Drawing 3. Do the same for the other Custom-fit guide helps eliminate chip-out side with your router. Whichever diameter router bit you use will be the size you should use in the future for making cutoffs.

3 trimming the edge of the guide A N

B O

C P FILENAME:Straight2_#100205683.eps Date: 5-06 Filename: 172 straightedges 1 D Q Lorna J. R LeMoine 4-21 E R S F ROUTER CIRCULAR fence base SAW G T

H U A N V I B O J W C P X K D Q Y L E R Z M S F ROUTER CIRCULAR With your circular saw’sSAW base riding against the fence, rip the waste off each guide (left). To G T use the guide, clamp it to a workpiece with the cutoff edge aligned on your mark. Set the saw blade to the appropriate depth and make the cut (right). H U V I woodmagazine.com 11 J W X K Y L Z M

FILENAME:Straight2b_#100205685.eps Date: 5-06 Filename: 172 straightedges 1 Lorna J. R LeMoine 4-21

FILENAME:Straight2b_#100205685.eps Date: 5-06 Filename: 172 straightedges 1 Lorna J. R LeMoine 4-21 At-the-ready router rest

This simple support offers you convenience and time savings for handheld work.

asting valuable time waiting for your router bit to stop spinning Wbefore you can set the router down? Would you like your router wrenches and bits near the project you’re working on for a speedy change? Address both concerns simultaneously by building this handy plywood router rest. Place your powered-down router in the U-shaped opening in the shelf support to shelter the still-turning bit safely away from both your worktop and your hands. To build this simple project, cut the pieces to the sizes noted on the drawing below right. Then, cut or rout a 3/4" groove 1/4" deep in the side pieces where shown. Drill the router-bit shank holes, and cut the kerfs in the base to customize it to organize your bits and wrenches. Drill countersunk mounting holes and assemble the pieces. Note: All stock ¾" ¾" grooves ¼" deep ½" from top edge A short section of dowel in the base works nicely to hold an extra collet. Add a clear SHELF 20° bevel SUPPORT finish, if desired. 7" R=1 ⁄" 3" SIDE Project design: Chuck Hedlund, WOOD® magazine Master Craftsman

7 ⁄" 3 ⁄" 20° 2½" 1⁄" ⁄" pilot hole ¾" deep SIDE 7½" 1½"

¼" holes 20° bevel 7" ⁄" deep Become an expert at the ⁄" shank hole, countersunk 4¼" router with our collection of on bottom face ¼" dowel 2¾" how-to videos at: 2" long woodmagazine.com/routertips BASE 1½" 1½" 1¾" #8 x 1½" F.H. wood screw ½" hole ⁄" deep

▲ 1" Kerfs cut to t wrenches

12" ¾" 1⁄"

12 Great Projects for Your Shop

100204849_#100204849.ai 2-09

FILENAME:100205229_GIFYRCaddy.eps Date: 11-05 Lorna J . Hang-and-go lathe-tool holder

When you create a mountable chisel caddy, who says it has to stay in one place?

his quick-to-make project slides between the rails in the lathe bed T(known as the ways) and cradles turning tools within arm’s reach. When not in use, it hangs on the wall, out of the way. Feel free to customize it for the type and number of turning tools you own. To size your tool holder, first measure the overall length of your turning tools to determine the length for the backboard (A). The one here is 21", just a bit shorter than most of the tools. Now, measure from the butt end of the handles to the ferrules (the rings on the handles near the blades). those lines, where dimensioned on part B, fit most lathes, but check the distance This determines the distance between the below. Drill holes to match the ferrules in between the ways on your lathe. The cleat upper rest (B) and base (D), as shown. one strip and to match the handles in the needs about ¼" clearance to slide easily. Next, measure the diameter of each other. Rip the rests (B, C) to width and Make the wall-mount parts (H, I) and tool’s ferrule and of each handle 2" from attach them to the backboard. Then, add secure this assembly to a wall stud. the butt end. Cut two 2×10¾" plywood the base (D). A screw in each edge of the strips to make the upper rest (B) and lower backboard retains a 10" miniature bungee Project design: Jeff Mertz, WOOD® Magazine rest (C), and mark lines 1¼" from one cord that secures the tools. edge. Lay out hole centerpoints along The cleat and retainer (E, F) are sized to

BED MOUNT 1¼" Mount E/F centered on backboard , #8 x 2¼" F.H. A ½" 4" from top edge. A Materials List wood screw F Length of FINISHED SIZE determined by Part T W L Matl. Qty. E length of tools A backboard 3⁄4" 103⁄4" 21"** BP 1 1¼" WALL B* upper rest 3⁄4" 11⁄4" 103⁄4" BP 1 MOUNT A B C lower rest 3⁄4" 11⁄4" 103⁄4" BP 1 3" 3 3 1¾" D base ⁄4" 2" 10 ⁄4" BP 1 E cleat 15 ⁄16" 11⁄4" 9 3⁄4" P 1 #8 x 1¼" F.H. 2½" I 1" wood screw F retainer 1⁄2" 2" 9 3⁄4" BP 1

G base block 1 1⁄2" 13⁄4" 4" P 1 H Equal to distance H hanger strip 3⁄4" 2 1⁄2" 9 3⁄4" BP 1 #8 x 1¼" F.H. Mount H/I to wall by driving #8 x 3" F.H. from tool’s wood screw Miniature butt end I hanger cap 3⁄4" 3" 9 3⁄4" BP 1 wood screws into a stud. bungee cord to ferrule *Parts initially cut oversize. See the instructions. #8 x 1" R.H. wood screw **Actual length determined by length of tools 10¾" Materials key: BP–birch plywood, P–pine. Supplies: #8×11⁄4" flathead wood screws (10), #8×21⁄4" G 2" 1½" flathead wood screws (2), #8×3" flathead wood screws (2), C #8×1" roundhead wood screws (4), 10" bungee cord. 2" 1¾" D #8 x 1¼" F.H. wood screws

woodmagazine.com 13

WD324814.ai Date: 3-09

FILENAME:148LatheGIFY .eps Date: 1-03 Lorna J. Easy-access router-bit storage

Combine pullout shelves with a clear-view window in one well-ordered cabinet.

o keep router-bit storage close at collection. Drill mounting holes and screw hand, this organizer works equally the ends to the shelves [Drawing 1a]. The Twell attached to the side of your finished shelf assemblies simply slide on freestanding router table or mounted on top of the dividers for ease in construction the wall. The handy storage unit’s four and use. TOP SECTION VIEW slide-out shelves make it easy to securely For mounting, remove the acrylic panel carry a variety of router bits anywhere from the front of the assembly and drill you’re working in the shop. four mounting holes through the plywood To construct the unit, cut the back, sup- back. Screw the assembly to studs in your port, five dividers, and acrylic front to size. shop wall or to the side of your router table, (We cut the 1/8"-thick clear acrylic with a and screw the acrylic panel to the dividers. 60-tooth, triple-chip carbide-tipped blade.) BACK 1⁄" CLEAR CountersinkACRYLIC the mounting holes in the Project design: David Riel, Huntington Beach, Calif. ¼" acrylic so theSHELF screw heads don’t protrude. Assemble the unit in the configuration Find numerous videos shown in Drawing 1, using just four screws on using routers at: to temporarily attach the acrylic front panel woodmagazine.com/routertips to theEN cabinet.D Cut the four hardwood shelves and ends TOP SECTION VIEW (one tall and three short) to size. Drill holes in the shelves to house your router-bit ▲

1a Top section view 1 Exploded View

#8 x 1½" F.H. wood screw BACK 1⁄" CLEAR ⁄" pilot hole SUPPORT ACRYLIC ⁄" deep ¼" #8 x 1" F.H. wood screw SHELF ⁄" shank hole, BACK countersunk ¼ x 18 x 19¾" plywood ⁄"

4" ½" hole 19¾" END TALL END ½" deep 4¾"

¾" ¼" hole 4" ½" deep

5⁄" 19¾" DIVIDERS ¾" ⁄ x 18 x 19¾" ⁄" round-overs clear acrylic SHELVES 2" #8 x 1½" F.H. wood screw SHORT ENDS ⁄" pilot hole SUPPORT ¾" Mounting #8 x 1" F.H. wood screw ⁄" deep holes 1⁄" ⁄17"¼ shank" hole, BACK4 ⁄" 2" countersunk ¼ x 18 x 19¾" plywood ⁄"

4" #8 x 2" F.H. wood screw ½" hole 19¾" TALL END ½" deep 17¼" 4¾" ⁄" shank hole, 4 ⁄" countersunk¾" ¼" hole 4" #6 x ½" F.H. ½" deep wood screw #8 x 1½" F.H. ⁄" ⁄" pilot hole wood screw ⁄" ¾" deep 5⁄" 19¾" 2DIVIDERS⁄" ¾" 14 ⁄ x 18 x 19¾" Great Projects for Your Shop ⁄" round-overs clear acrylic SHELVES 2" SHORT ENDS ¾" Mounting holes 1⁄" 17¼" 4 ⁄" 2" R OUTER BIT ORGANIZER #8 x 2" F.H. wood screw 100205337.ai 17¼" ⁄" shank hole, 4 ⁄" Date: 5-09 countersunk #6 x ½" F.H. FILENAME:168GIFY RoutBitHolder..eps wood screw #8 x 1½" F.H. Date: 9-05 ⁄" ⁄" pilot hole wood screw Lorna⁄ "J. ¾" deep 2⁄"

R OUTER BIT ORGANIZER

100205337.ai Date: 5-09 FILENAME:168GIFY RoutBitHolder..eps Date: 9-05 Lorna J. Round and ready drill-bit carousel

This rotating organizer goes slot locations [Drawing 1a]. Drill 5/8" start holes for the outside and middle slots and wherever you need it. 3/8" start holes for each inside slot. Then, scrollsaw or jigsaw between the holes to form the slots. Drill 5/8"-deep holes in the shelf to fit the shanks of your bits and ant to keep large drill bits and accessories and a 1/2" hole through the other hole-boring accessories base for screw access. close at hand and easy to find? Crosscut the dowels to length. Create a W 3 This compact carousel holds a multitude collar with a /4" hole in it. Assemble the of specialty bits, such as holesaws and unit [Drawing 1] and attach the bearing to Forstner bits, and swivels on a lazy-Susan the base, using the 1/2" access hole in the bearing for quick access. base to drive the screws into the shelf. To build one, use a compass to mark three 5"-radius circles on 3/4" plywood. Project design: Jim Harrold, Norwalk, Iowa Bandsaw and sand the discs to shape. For the top, locate and mark the nine curved

#8 x 1" F.H. wood screw 1 ⁄"-diam. knob ⁄" shank hole, countersunk ¾" hole ½" deep, centered in bottom TOP

R=5"

1 exploded view ¾" hole ⁄" pilot hole ¾" deep 1⁄"-diam. wood collar glued to underside of bit holder

¾" dowel 12" long 1a top detail Custom hole sizes to match your collection of bits and accessories 1⁄" ⁄" holes ½" dowel 3" long R=3" R=2 ⁄" R=4⁄" R=2⁄" R=5" SHELF R=4 ⁄" R=1⁄" R=5" ¾" hole, centered R=¾" R=1⁄" R=1¼" 6" lazy Susan #8 x ½" panhead wood screw

⁄" hole ¾" hole ⁄" pilot hole ½" deep BASE R=5"

#8 x ½" panhead ½" vinyl self-adhesive wood screw gripping pad ½" hole for screw access

woodmagazine.com 15

DRILL BIT CAROUSELTOP DETAIL FILENAME:100204910.ai Date: 5-09 Lorna J .

100204911.ai Date: 5-09

FILENAME:GIFYBitLZsusan2_#100204911.eps Date: 2-06 Lorna J. Workshop drawer organizer

Keep small tools and accessories in this convenient lift-out box.

o matter the size of your shop drawers, this compartmentalized Nbox keeps everything tidy. If need be, you can remove the box quickly to wherever you’re working. To build an organizer, first measure the width of the drawer you want the insert to fit. Make the overall width of the organizer ¼" less than the interior of the drawer. To accomplish this, measure the interior of the drawer (side-to-side) and cut the front and back (A) to this size minus 3/4". Cut the sides (B) and bottom (C) to size. Cut the grooves, dadoes, and rabbets in parts A and B, where dimensioned. Clamp the pieces together and cut the divider (D) to fit. Cut the drill-bit holders (E) to size, bevel-ripping one edge at 30° 1½" where shown, at right. Drill holes in the 1½" holders to fit your bit shanks. Drill mount- ½" ¼" hole 11" ¾" deep ing holes and screw the holders (E) in place 1¼" to the box bottom (C). We did not glue the holders (E, F) in place so we could resize 30° DRILL BIT or relocate them later. Cut the holders (F) E HOLDER to fit and drill shank holes in them. With 1" 1¼" DETAIL assembly complete, apply a clear finish to ¼" holes the insert and fit it into place. ¾" deep

E Project design: Kevin Boyle, WOOD® magazine 2 ⁄" 3" ¼" hole F *Length of A equals drawer 3¼" ½" *15" opening minus ¾". ¾" F Materials List ¼" ¼" rabbet ¼" deep FINISHED SIZE Wall cabinet T W L Matl. Qty. ¼" groove A ¼" deep ¼" groove ¼" deep A front and back 1⁄2" 21/4" *15" M 2 ¼" from 12½" 1¾" ¼" from bottom edge back edge B sides 1⁄2" 21/4" 13" M 2 ½" dado ¼" deep 1 1 C bottom /4" 12 /2" 15" P 1 B D 1 2 3 4 1 2 C D divider ⁄ " 1 / " 12 / " M 1 ½" 2¼" E* bit holders 11/2" 11/2" 11" M 2 ½" F* small holders 3/4" 3" 27/8" M 2 6¼"

3 A *Length of A equals drawer opening minus /4". 12½" Materials key: M–maple, P–plywood. ⁄" shank hole, B countersunk Supplies: 8×1" flathead wood screws. on bottom 13" #8 x 1" F.H. wood screw

¼" grooves ¼" deep ¼" from bottom edge

16 Great Projects for Your Shop

100204020.ai Date: 4-09 DRILL BIT DRAWER (Viewed from back)

FILENAME:154DrillBitDrawer.eps Date: 8-03 Lorna J . Movable task-light support

Let there be light wherever you want it with this cleat- mounted vision aid.

or maximum efficiency in wall- mounted storage, a cleat system is F hard to beat. Strips of 1x3 stock bev- eled at 45º at the top and anchored to the shop walls mate with matching strips attached to just about anything from cabi- nets to tables for easy wall mounting. This easy-to-build light support fits and locks onto the same cleat for placement wherever it’s needed. To make this shop helper, cut the cleat and the turnbutton from solid stock and the shelf, bracket, and back from 3/4" plywood. Drill countersunk screw holes and a hole in the shelf to fit your light’s mounting post. The bottom edge of the back must be flush with the bottom edge of the wall- hung cleat when in place. Adjust if needed. Glue and screw the support together and then position the assembled light support where you need it. Drop the light into place in the hole and swivel the turnbutton, as shown in the photo below, to secure the support to the wall cleat. For use in a shop without a cleat system, #8 x 1½" F.H. wood screw construct the project so the shelf’s rear 1 ⁄" #8 x 1¼" F.H. edge is flush with the rear surface of the 4" wood screw back. Omit the turnbutton and cleat, and 10" screw the assembled support to the wall, 4" centered over a stud. Then, slip the lamp 1" extension into the hole in the shelf. R=2" SHELF ¾" CLEAT SUPPORT Project design: Kevin Boyle, WOOD® magazine Hole to t lamp extension 3"

45° bevel 6" 3" #8 x 1½" F.H. ⁄" 1" BRACKET wood screw

5½" BACK *All shank holes are 4" ⁄" countersunk, with ⁄" pilot holes.

R=⁄" Note: Cleat support and turn button ½" made from ¾" solid stock. All other parts are ¾" plywood. TURNBUTTON ½x ¾x 1⁄" #8 x 1¼" F.H. wood screw

woodmagazine.com 17

100204052.ai 4/09

FILENAME:155HolderGify.eps Date: 9-03 Lorna J. Wall-hung tape dispensers

Hang them at a convenient height and lift off only the dispensers you need.

his tape center gives easy access to #8 x 1" F.H. wood screw Hacksaw blade crosscut tape two ways: Just pull tape from a to width of tape plus ⁄" dispenser seated in the wall mount, ½" T #19 x ½" wire nail or removeWALL the MOUNT dispenser to use anywhere. First, determine how14 many" tape rolls you ⁄" hole ⁄" from ends, centered use in your shop. Then, make a dispenser #8 x 2" F.H. wood screw for each, as dimensioned¾" on Drawing 1. centered over stud ¾" Note that the interior width of each dis- ¼ x 1⁄" diam. ¾" 1 or 2⁄" diam. penser is /16" wider than the¾ "roll of tape it holds. Create the discs to be glued to the ¼" dispenser sides by tracing the opening of Width of 3¾" tape plus ⁄" each tape roll onto 1/4" hardboard.¼ " Cuthardboard them out3 1⁄/8" smaller than the opening on #8 x ¾" F.H. 3⁄" a bandsaw or scrollsaw or with a circlewood cut- screw ter. Cutting the discs⁄ a x bit ⁄ "smaller than the 2¾" rabbet 3¾" tape roll’s2¼ "inside diameter allows them to ⁄" pilot hole rotate freely once they are glued in place. ¼" ½" deep In our shop,#8 xall ¾ "the F.H .rolls of tape used either ¾" wood screws 3 7 a 1 /8"- or 2 /8"-diameter disc. ⁄" shank hole, Width of Removable side, countersunk When assembling each dispenser, glue 2¾" tape plus ⁄" allowing access to ¼"-diam. only one side in place.add or To replace load atape. new roll of 8¾" adhesive-backed tape, simply remove the two screws from 1 Exploded Viewrubber bumper #8 x 1" F.H. wood screw Hacksaw blade crosscut one side to gain access. A piece of hacksaw DISPENSER to width of tape plus ⁄" blade serves as a cutter. ½" Build the wall mount as dimensioned #19 x ½" wire nail WALL MOUNT and attach it to your shop wall. To hang a 14" ⁄" hole ⁄" from dispenser from the wall mount, lift the front #8 x 2" F.H. ends, centered end of the dispenser while inserting the top wood screw ¾" centered over stud ¾" edge of the back into the rabbeted cleat of ¼ x 1⁄" diam. ¾" the wall mount, as shown in Drawing 2. or 2⁄" diam. ¾" ¼" Project design: Jeff Mertz, WOOD® magazine Width of 3¾" tape plus ⁄" ¼" hardboard 3⁄" #8 x ¾" F.H. 3⁄" 2 Inserting Dispenser wood screw ⁄ x ⁄" 2¾" rabbet 3¾" 2¼" ⁄" pilot hole DRYWALL ¼" ½" deep #8 x ¾" F.H. ¾" WALL Rabbeted cleat wood screws ⁄" shank hole, Width of STUD Removable side, countersunk 2¾" tape plus ⁄" allowing access to ¼"-diam. add or replace tape. 8¾" adhesive-backed DISPENSER rubber bumper DISPENSER

WALL MOUNT

18 100205789.ai Great Projects for Your Shop Date: 5-09

FILENAME:164GIFY TapeHolder.eps Date: 2-05 Lorna J.

DRYWALL

WALL Rabbeted cleat STUD

DISPENSER

WALL MOUNT

100205789.ai Date: 5-09

FILENAME:164GIFY TapeHolder.eps Date: 2-05 Lorna J. Portable glue/towel center

A helper that’s equally at home on a wall or at arm’s reach on your workbench. ¾"

G ang this handy organizer on a cleat 1½" system, and quickly remove it and Hmove it wherever you’re working to keep your glue and cleanup supplies 45° close at hand. For this shop aid, cut parts 1 1 A–D from /2" plywood, part E from /4" ⁄" hardboard, part F from 1/2" solid stock, and part G from 3/4" stock to the sizes noted on Drawing 1. ReferGLUE to Drawing/ PAPER 1a TO for machinWEL HOLDER- ing the cleat. Cut the dowel groove in the supports (D) to shape. Cut the dadoes, rabbets, and grooves, where illustrated, in parts A, B, and F. Assemble the unit. Cut a 3/4" dowel to fit between the side pieces and in the dowel groove. Screw the cleat to the back (F) with the top edges of F and G flush. To learn more about this cleat system, visit woodmagazine.com/cleatsystem

Project design: Kevin Boyle, WOOD® magazine

1a cleat Detail #8 x 1" F.H. wood screw 1 Exploded View ¾" 14" G ½" 1½" ½ x 3¼ x 3½" plywood 5¾" G 2¾" ½" 2¾" 4" 1½" ½" dadoes ¼" deep 45° bevel C ⁄" shank hole, countersunk on back A ½" rabbet 45° B B 3½" F ¼" deep 6" ⁄" ¼" E ¼" groove 13½" ½" ¼" deep ¼ x 6 x 13½" ¼" from A 12½" GLUE / PAPER TO WEL HOLDER hardboard bottom edge 4" ¾" dowel D 12⁄" long ½ x 4½ x 6" 1¼" plywood F 4½" 3" 14" #8 x ¾" F.H. R=½" wood screw D ½" ⁄" shank hole, countersunk 6" 6"

woodmagazine.com 19 #8 x 1" F.H. wood screw 14" G FILENAME:156GifyTowel.ai ½" 1½" ½ x 3¼ x 3½" plywood 5¾" Date: 5-03 2¾" ½" Lorna J . 2¾" 4" ½" dadoes ¼" deep 45° bevel C ⁄" shank hole, countersunk on back A ½" rabbet B B 3½" F ¼" deep 6" ¼" E ¼" groove 13½" ½" ¼" deep ¼ x 6 x 13½" ¼" from A 12½" hardboard bottom edge 4" ¾" dowel D 12⁄" long ½ x 4½ x 6" 1¼" plywood F 4½" 3" 14" #8 x ¾" F.H. R=½" wood screw D ½" ⁄" shank hole, countersunk 6" 6"

FILENAME:156GifyTowel.ai Date: 5-03 Lorna J . Edge-protecting chisel rack 1" hanger hole with 13½" 1" ⁄" chamfer Keep chisels handy, and their tips shielded 1¾" ⁄" hole (Hole sized to 14" t chisel ferrule) ¾" rabbets ⁄" deep #8 x 1½" F.H. 1¼" wood screws 1" 1½" 6¾" 1⁄" ⁄" 3"

13" 3" 13½" ⁄ x ¾ x 13½" 2" spacer ⁄" chamfer ⁄" shank hole, countersunk on back face

o keep chisels sharp and easy to the shelf and the chisel holes. Chamfer the find, keep them in this basic storage shelf edges and rabbet the front where Track. Cut the front, back, sides, shown. To finish, drill the mounting holes, shelf, and spacer to the sizes shown on the and glue and screw the rack together. drawing. Locate and bore the hanger holes in the back and the chisel holes in the Project design: Kevin Boyle, WOOD® Magazine shelf. (You may have to adjust the hole size in the shelf to fit your chisels.) Now, saw out the waste between the front edge of OLDSF7_#100504707_#.eps pencil box with sharpener support Some shop accessories o build this handy holder, cut the CHISEL RA CK SF7_#100504707_#100504707.aifront, back, sides, bottom, and should go together, Date:and 3-09 this Tspacer to the sizes shown on the drawing from ¾" stock. Drill the mounting project sees to it. FILENAME:166ShopFixture7.epsholes and rabbet the front as shown. Glue Date: 8-05 and screw the parts together. Complete Lorna J . the project by attaching a pencil sharpener to the bottom.

Project design: Kevin Boyle, WOOD® Magazine

1½" 5" 1" hanger hole with 1" ⁄" chamfer ⁄" shank hole, countersunk on back face

¾" rabbets #8 x 2" F.H. ⁄" deep wood screws ¾"

4¼" 3¼" 12" 4¼" 3½"

6" 5"

3⁄"

⁄ x ¾ x 5" spacer

20 Great Projects for Your Shop

PENCIL BOX WITH SHARPENER SUPPORT

SF8_#100504708_#100504708.ai Date: 3-09

FILENAME:166ShopFixture8.eps Date: 8-05 Lorna J . Handy hardware bin

Corral plastic bins for a great small-parts organizer.

eep loose hardware and screws organized with this holder for plastic hardware bins. First, cut the front, K 27" 1" hanger hole with ⁄" chamfer back, ends, and spacer to size from ¾" stock. Adjust component sizes as needed 1" #8 x 1½" F.H. wood screw to accommodate your bins. Next, cut the 5½" bottom to size from 1/4" hardboard. Mark ⁄" shank ¾" rabbet ¾" the centerpoints, drill the holes, and hole, ⁄" deep ¾" rabbet counter- chamfer the edges. Then rout or cut 1/4" ⁄" deep sunk on back face grooves 3/8" deep 1/4" from the bottom edge of the front, back, and end pieces. 1½" Rabbet the front and back where shown. 2¼" SPACER Finally, drill hanger holes and glue and ⁄ x ¾ x 27" screw the pieces together. 26¼" 1½" ¼" 27" 6½" 5½"

¼" grooves ⁄" deep ¼" from 1½" 6½" Hanging glue box bottom edge

A great item to help glue his simple box keeps glue and glue on the back, drill the holes, and chamfer brushes close at hand. The 1" hanger their edges. Cut or rout 1/4" grooves 3/8" and supplies stick around Tholes come in handy, especially for deep 1/4" from the bottom edges of the moving the box to the project assembly back, front, and end pieces to house a when you need them. area and returning it to the wall later. hardboard bottom. Rabbet the front where Cut the front, back, ends, spacer, and shown. Assemble the pieces and add the divider to the sizes listed on the drawing spacer to the back. from ¾" stock. Cut the box bottom to size from 1/4" hardboard. Mark the centerpoints 100504705.ai Date: 5-09 10" 1" 1" hanger hole with ⁄" chamferHARD WARE BI N FILENAME:166ShopFixture5.eps Date: 8-05 1½" ¾" Lorna J. SPACER ¾" ⁄ x ¾ x 10"

¾" rabbets 10" ⁄" deep 3½" ⁄" shank hole, countersunk 4" 4¼" 4" 4" 9¼" ¼" #8 x 2" F.H. 5⁄" wood screw 10" ¼" grooves ⁄" deep ¼" from bottom edge woodmagazine.com 21

100504706.ai Date: 5-09

GLUE TOT E

FILENAME:166ShopFixture6.eps

Lorna J. Best-Ever Plans for , Workshop Tools woodworking1100+ plans at & Accessories woodmagazine.com/plans

® from the editors of WOOD magazine

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Mobile Storage Space-Saving Work Center Get’r-Done Shop Cart Lumber Storage Rack Shop-in-a-Box Tool Cabinet Plan DP-00321 $2.75 Plan DP-00168 $6.95 Plan DP-00486 $4.95 Plan DP-00135 $7.95 Plan DP-00518 $5.95

Download any of these woodworking plans for the prices listed, or view a larger image, at woodmagazine.com/plans To have paper plans mailed directly to you (add $3 per plan plus S+H), call toll-free 1-888-636-4478. Please have your credit card available. 22 Great Projects forGPPM2010 Your Shop